United States Environmental Protection Agency Industrial Environmental Research Laboratory Research Triangle Park NC 27711 EPA-600/7-78-112 June 1978 Research and Development Rapping Reentrainment in a Near Full Scale Pilot Electrostatic Precipitator Interagency Energy/Environment R&D Program Report ------- RESEARCH REPORTING SERIES Research reports of the Office of Research and Development, U.S. Environmental Protection Agency, have been grouped into nine series. These nine broad cate- gories were established to facilitate further development and application of en- vironmental technology. Elimination of traditional grouping was consciously planned to foster technology transfer and a maximum interface in related fields. The nine series are: 1. Environmental Health Effects Research 2. Environmental Protection Technology 3. Ecological Research 4. Environmental Monitoring 5. Socioeconomic Environmental Studies 6. Scientific and Technical Assessment Reports (STAR) 7. Interagency Energy-Environment Research and Development 8. "Special" Reports 9. Miscellaneous Reports This report has been assigned to the INTERAGENCY ENERGY-ENVIRONMENT RESEARCH AND DEVELOPMENT series. Reports in this series result from the effort funded under the 17-agency Federal Energy/Environment Research and Development Program. These studies relate to EPA's mission to protect the public health and welfare from adverse effects of pollutants associated with energy sys- tems. The goal of the Program is to assure the rapid development of domestic energy supplies in an environmentally-compatible manner by providing the nec- essary environmental data and control technology. Investigations include analy- ses of the transport of energy-related pollutants and their health and ecological effects; assessments of, and development of, control technologies for energy systems; and integrated assessments of a wide range of energy-related environ- mental issues. REVIEW NOTICE This report has been reviewed by the participating Federal Agencies, and approved for publication. Approval does not signify that the contents necessarily reflect the views and policies of the Government, nor does mention of trade names or commercial products constitute endorsement or recommendation for use. This document is available to the public through the National Technical Informa- tion Service, Springfield, Virginia 22161. . ------- EPA-600/7-78-112 June 1978 Rapping Reentrainment in a Near Full Scale Pilot Electrostatic Precipitator by Grady B. Nichols Southern Research Institute 2000 Ninth Avenue, South Birmingham, Alabama 35205 Contract No. 68-02-1875 ROAPNo. 21ADL-027 Program Element No. 1AB012 EPA Project Officer: Leslie E. Sparks Industrial Environmental Research Laboratory Office of Energy, Minerals, and Industry Research Triangle Park, NC 27711 Prepared for U.S. ENVIRONMENTAL PROTECTION AGENCY Office of Research and Development Washington, DC 20460 ------- DISCLAIMER This report has been reviewed by the Industrial Environ- mental Research Laboratory, U. S. Environmental Protection Agency, and approved for publication. ; Approval does not signify that the .contents necessarily reflect the views"and policies of the U. S. Environmental Protection Agency, nor does mention of trade names or ,• commercial products constitute endorsement or recommendation "for-use. -11- ------- ABSTRACT This report summarizes the results of an initial study to define the reentrainment characteristics of fly ash being removed from the collection electrodes of an electrostatic precipitator by rapping forces. The details of the study are presented in EPA-600/2-76-140, one of the Environmental Protection Technology Series of Documents entitled "Rapping Reentrainment in a Nearly Full-Scale Pilot Electrostatic Precipitator", May 1976. This study was conducted at the Rosemont Laboratory of FluiDyne Engineering in Minneapolis, Minnesota under the sponsorship of the Industrial Environmantal Research Laboratory of the U. S. Environmental Protection Agency at Research Triangle Park, N. C. -111- ------- CONTENTS Disclaimer ii Abstract iii Figures and Table v 1. Introduction 1 2. Test Program 3 3. Computer Model Modification 11 4. Recommended Research 12 IV ------- FIGURES AND TABLE Number Paqe Figure 1 Figure 2 Figure 3 FluiDyne test facility. Various views of FluiDyne pilot precipitator Block diagram of experimental layout for rapping reentrainment study Table I FluiDyne Test Program 4-5 ------- SECTION I INTRODUCTION This document constitutes the final report under Contract 68-02-1875. The technical results of the study were published in Report E.P.A. 600/2-76-140, "Rapping Reentrainment in a Nearly Full-Scale Pilot Electrostatic Precipitator." This report sum- marizes the project including a discussion of the inclusion of rap- ping reentrainment in the E.P.A. electrostatic precipitator model. The study included a preliminary laboratory investigation to eval- uate the measurement techniques; a preliminary field study at the FluiDyne Engineering pilot precipitator to evaluate the pre- cipitator; a detailed field study to provide the rapping reen- trainment data with analyses and finally, inclusion of rapping re- entrainment data into the EPA-SRI electrostatic precipitator com- puter systems model. The overall objective of this research program was to ob- tain the data necessary to provide a method for representing rap- ping reentrainment in the computer systems model. The fundamental processes in an electrostatic precipitator, including charging, particle transport and collection can be mathematically modeled from first principles. This, however, does not apply to reentrain- ment. The quantity and particle size distribution of the reentrain- ed material must be determined in order to include these data in the computer system model. This report discusses the results of an experimental investi- gation of rapping reentrainment using a nearly full-scale pilot precipitator at FluiDyne Engineering Corporation's Rosemont Labora- tory. The work had three main objectives: (1) a study of the basic mechanics of removal of dry dust by rapping and the variations in the removal mechanisms with changes in dust properties, (2) quanti- fication of rapping reentrainment in terms of the percentage of the total losses, and of the particle size distribution of the reentrain- ed dust, and (3) modification of the E.P.A. - S.R.I, computer sys- tems model to include losses due to rapping reentrainment into the computation process. The laboratory study carried out under Task I utilized the E.P.A. pilot scale electrostatic precipitator located at S.R.I, to evaluate the proposed measurement techniques for use on the FluiDyne ------- facility. The collection electrodes in the pilot E.S.P. were instrumented with an accelerometer system that had been calibrated by the use of an electromagnetic shaker facility. Experiments were conducted to evaluate the ability of the in- strumentation to discern the presence of rapping puffs. Individual impactors were operated during the particulate collecting period and during the rapping period to check their operation. Movies of the behavior of the dust layer were made during rapping to evaluate that system. The experiments showed that the equipment could be used to make measurements to identify the contribution of rapping puffs to the overall emission in the FluiDyne pilot precipitator facility. Tasks II and III are covered in detail in Report No. E.P.A. - 600/2-76-140, Rapping Reentrainment in a nearly full scale Pilot Electrostatic Precipitator, dated May, 1976. These two tasks are summarized in this report. ------- SECTION II TEST PROGRAM A ten day test program was conducted at the FluiDyne test site as indicated in Table I. A schematic of the Fluidyne facility is shown in Figures 1 and 2. Figure 3 shows a block diagram of the test program. The experimental program included a fundamental study of the mechanics of removal of dry dust by rapping and the quantification of rapping reentrainment in terms of the percentage of total emis- sions and particle size distribution of the reentrained dust. The percentage of dust removed from the plates depended on the mass per unit area of dust collected on the plates as predicted by theory. The build-up of a residual dust layer was observed. A residual dust layer developed that could not be removed with the available rap- ping intensities (up to 20 G's). The contribution of rapping reentrainment to total emissions ranged from 53% to 18%, depending on rapping conditions. These percentages corresponded to 5.4% and 2.7%, respectively, of the dust collected on the plates being emitted during plate rapping. A significant decrease in total rapping emissions was obtained by increasing the time interval between raps. This decrease was re- lated to the resulting larger mass per unit area collected on the plates before rapping. Particle size distribution measurements showed that the mass median diameter of the particles emitted during the raps increased with increased time between raps. As expected, this produced lower overall emissions. The increase in the size of the particles emit- ted during rapping was ascribed to an increase in the agglomeration of the particulate removed from the precipitator plates with the re- spective increase in the mass per unit area collected on the plates (thicker dust layers) before the plates were rapped. A major por- tion of the reentrained material resulted from hopper "boil-up". A small portion of the dust would pass directly through the precipi- tator in a short burst at the velocity of the gas passing through the unit, while the remaining portion of the material was observed to fall into the hoppers, to rebound, and finally to escape slowly over the baffles and out of the precipitator. This produced a significant vertical concentration gradient in the dust emitted from the precipitator due to rapping reentrainment. ------- TABLE I FLUIDYNE TEST PROGRAM June 16 June 17 June 18 June 19 June 20 June 23 Unloaded and set up equipment. Clean plate rapping accelerations, equipment checked. Conditioned impactor substrates, tested for weight gains, clean plate V-I characteristics, gas velocity at sampling locations, adjusted for desired flow, measured gas velocities at entrance and exit planes of the precipitator, tested dust feed system, tested real time sampling system. Measured inlet particle size distribution, inlet mass loading, and tested load cells. Checked mass trains and impactors to detect rapping puffs. Measured dust resistivity and adjusted for 1010 ft-cm. Ran efficiency test with following conditions: Dust feed Current density - 23 nA/cm2 Gas velocity between plates - ^0.91 m/sec Rapper intensity - 80% of maximum Rapper interval - 30 minutes inlet - 60 minutes outlet Start intensive test program. All variables except rapping intensity and time interval between raps were held constant. The quantity of dust reentrained and the variables affecting reentrainment were measured. Test 1 150 minutes between raps, rapping in- tensity 100% of maximum, 1 rap Test 2 120 minutes between raps, rapping in- tensity 100% of maximum, 1 rap ------- TABLE I FLUIDYNE TEST PROGRAM (continued) June 24 June 25 June 26 June 2 7 Test 3 12 minutes between raps, rapping in- tensity 80% of maximum, 6 raps Test 4 32 minutes between raps, rapping in- tensity 80% of maximum, 3 raps Test 5 12 minutes between raps, rapping in- tensity 100% of maximum, 6 raps Test 6 32 minutes between raps, rapping in- tensity 100% of maximum, 3 raps Test 7 52 minutes between raps, rapping in- tensity 80% of maximum, 3 raps Test 8 52 minutes between raps, rapping in- tensity 100% of maximum, 2 raps (rain and wind knocked out electrical power and burners, test was terminated 15 minutes after second rap) Test 9 Deleted due to internal electrical short in the precipitator. ------- CTi NOMINAL 48 IN. WIDTH FOR (5) PASSAGES EXPANSION TO TEST PRECIPITATOR STEAM TO MATCH CONDITIONS FLOW RATE TO 45,000 SCFM TEMP-AMBIENT-40O°F HUMIDITY TO 8% ASH FROM H2S04 + HOT AIR (650°F) CLIENT'S STATION (FROM PRECIP. HOPPERS) TO MATCH CLIENTS CONDITIONS Figure 1. FluiDyne test facility ------- TYPICAL FLOW 9 FT/SEC 300°F 35000ACFM SCA5I.4 * 9 ACCELEROMETERS ARE MOUNTED ON PLATE 4 NORTH EAST SECTION A-A WEST CHANNEL NO PLATE ROW NUMBER PLATE ROWS 1, 2, & 6 EXPANDED METAL PLATES ROWS 3, 4. & 5 SOLID PLATES 2-1 and 2-3 WERE SHORTENED.5 METERS Figure 2. Various views of FluiDyne pilot precipitator. ------- ELECTRICAL CHARACTERISTICS RAPPING VARIABLES DUST LOAD ON PLATES PLATE ACCELERA- TION GAS ANALYSIS SO3, SO2, H2O TEMPERATURE 00 RESISTIVITY MEASUREMENT MASS LOADING TIME INTEGRATED PARTICLE SIZE MEASUREMENTS VELOCITY DISTRIBUTION TWO SETS AT 3 LOCATIONS: ONE TO MEASURE DURING RAPS AND ONE TO MEASURE BETWEEN RAPS. TWO SEPARATE UNITS: ONE TO LOOK AT LOWER HALF OF THE PRECIPITATOR OUTLET AND ONE TO LOOK AT UPPER HALF OF THE PRECIPITATOR OUTLET. PRECIPITATOR OBSCURATION METER TIME INTEGRATED PARTICLE SIZE MEASUREMENTS MASS LOADING UPPER HALF CAMERA AND LIGHTING MASS LOADING LOWER HALF HOPPER SAMPLES •• REALTIME PARTICLE SIZE MEASUREMENTS Figure 3. Block diagram of experimental layout for rapping reentrainment study. ------- The fractional collection efficiencies of the precipitator excluding and including rapping reentrainment emissions were de- termined and compared with theoretical values. Rapping reentrain- ment increased the discrepancy between theory and measured frac- tional collection efficiencies for particles larger than 5ym. However, rapping reentrainment did not account for all of the dis- crepancy. Reentrainment between raps and sneakage through the nonelectrified regions of the precipitator were considered to con- tribute to overall emissions. The experiments provided data that suggested some problems in detailed mathematical modelling of rapping reentrainment. It is difficult to predict the quantity of dust removed from a plate by an individual rap. The calculation of the recollection of the re- entrained material is difficult for several reasons. The particle size distribution of the reentrained particles can be changed sig- nificantly by moderate changes in rapping variables and hopper boil- up also contributes to the difficulty in modelling since much of the reentrained material is introduced into nonelectrified regions of the precipitator. However, the experiments supplied some infor- mation that could be used to estimate the effects of rapping reen- trainment on the size of a precipitator required for a given col- lection efficiency. Two simplified assumptions were used to estimate the signifi- cance of rapping reentrainment. The first assumption was that a fixed percentage of rapping emissions was emitted from a precipita- tor independent of the size of the unit, while the second assump- tion was that the same percentage of material was reentrained and emitted from each section due to rapping. The recollection effi- ciency for the reentrained material was assumed to be the same as that for previously uncollected material for all sections. The estimates based on the above showed that the increase in precipi- tator size needed to recover the rapping emissions can range from 6% to greater than 80% of the original size of the unit for the cases considered. Rapping reentrainment emissions computed on the basis of the percentages obtained at FluiDyne account for a signifi- cant portion of precipitator emissions. Initially, four weeks of tests were planned for Tasks II and III. At the conclusion of the test period described previously in Table I, the status of the test results and the funding situation was reviewed. It was determined that: 1. Additional funds would be required to conduct two more weeks of tests. 2. The results of the tests to date provided suffi- cient data for the pilot test facility. Therefore additional pilot scale tests were cancelled. ------- During the period of this research contract, the Electric Power Research Institute had funded a study of Rapping Reentrain- ment at a number of full scale installations. The Industrial En- vironmental Research Laboratory of E.P.A. and the E.P.R.I. agreed to cooperate on the rapping reentrainment study. The result of the E.P.A. pilot study served as a guide for establishing the test program for the E.P.R.I. field tests. This field test program included rapping reentrainment measure- ments at six installations described as follows: - Two cold side units collecting fly ash from the com- bustion of low sulfur Western coal. Two cold side units collecting fly ash from the com- bustion of high sulfur Eastern coal. One hot side unit collecting fly ash from the com- bustion of low sulfur Western coal. One hot side unit collecting fly ash from the com- bustion of low sulfur Eastern coal. The results from these tests have been reported, in draft form, to the E.P.R.I. in a document entitled "Electrostatic Precipitator Rapping Reentrainment and Computer Model Studies", August 15, 1977. A copy of this draft report was submitted to the Industrial En- vironmental Research Laboratory, Environmental Protection Agency, Research Triangle Park, North Carolina for review. 10 ------- SECTION III COMPUTER MODEL MODIFICATION Task IV of the E.P.A. contract was to include rapping reen- trainment into the E.P.A. - S.R.I, electrostatic precipitator com- puter systems model. The results of the measurement program con- ducted at the above six full scale field installations have been reviewed, analyzed and used to develop a calculation procedure for approximating the magnitude of rapping reentrainment emissions as follows: 1. The dust concentration removed from the flue gas by the last field was estimated from the Deutsch equation and the overall mass efficiencies obtained during the test programs at each installation. 2. The overall mass emission (in mass/volume of flue gas) attributable to rapping were graphed as a function of the dust calculated to have been removed by the last field for each of the six installations. 3. The rapping emissions were represented as a function of the dust removal in the last field by a simple ex- ponential expression, and the expression was programmed into the computer model. 4. Data from the six installations were used to construct an average apparent size distribution of a rapping puff. This size distribution is then applied to the mass emis- sions caused by rapping and calculated in step 3 above to obtain a histogram of rapping emissions as a function of particle size. 5. The size dependent rapping emissions are then added to those calculated by the model to originate from the steady-state, non-rapping precipitator process. A draft report has been transmitted to I.E.R.L. that de- scribes this expanded version of the computer systems model. This updated a previous report No. E.P.A. - 650/2-75-037, "A Mathemati- cal Model of Electrostatic Precipitation", dated April, 1975. This new version of the model contains the currently available rapping reentrainment computer program modifications as well as other modi- fications developed under E.P.A. Contract 68-02-2114. 11 ------- SECTION IV RECOMMENDED RESEARCH The method utilized to represent size-dependent rapping loss- es in the computer model described previously in this report is an empirical one based on an average apparent size distribution of particulate emissions attributable to rapping. The size distribu- tion data were obtained from full-scale field tests. The total mass emissions from rapping are also represented empirically. The procedure used is based on a simple relationship between the mass calculated to have been collected in the last field of the precipi- tators and the rapping emissions measured during field tests. Al- though this procedure represents a useful interim technique for estimating rapping reentrainment in precipitators, it is desirable to include rapping into the model in a more fundamental way for modeling precipitator performance. The ESP computer model program calculates particle collection rates for representative particle sizes as a function of length through the precipitator. This basic calculation procedure is suitable for including a dynamic representation of reentrainment resulting from a particular rapping system design. The particulate reentrained as a result of rapper activation in a given field at a given point in time may be thought of as a pulse in the particulate concentration in the field under consideration. A technique to model the reentrainment of dust from first principles should in- clude consideration of the following problems: 1) What are the size distributions of the reentrained par- ticulate from the various fields and what fraction of the collected mass is reentrained? 2) To what extent is the particle charging process disrupted by the sudden reintroduction of a significant particulate concentration? 3) To what extent are the reentrained particle remixed with the gas stream? 4) What collection mechanism can best represent the recapture of reentrained particulate? Since a Deutsch-type mechanism is valid only for smaller particles which follow the mo- tion of the gas stream, we anticipate that the reentrained 12 ------- material (dominated by the larger agglomerate, >5 jam diameter) will require a different mathematical ex- pression to represent the trajectory. 5) Does the pulse of dust resulting from a rapper activa- tion cause a momentary decrease in sub-tenth micron par- ticulate emissions due to the sudden increase in poten- tial surface area for agglomeration. 6) What relationships can be formulated to represent the cumulative mass size distribution of the reentrained material as a function of the following variables? a) Rapping interval b) Ash and gas composition, temperature, and size distribution of collected dust, which determine dust cohesive and adhesive properties. c) Plate acceleration d) Plate response e) Mass loading of dust on plate f) Plate geometry g) Gas velocity h) Electrical holding forces It is apparent from the nature and the complexity of the re- entrainment process that some degree of empiricism must be incor- porated into a modeling approach. However, since the existing mathematical model is able to simulate the collection process with reasonable accuracy, a logical approach would be to use the exist- ing program structure as a basis for calculating the recollection of reentrained dust. Once this task is accomplished, it would be possible to examine the effect of rapping frequency and certain precipitator design parameters on overall collection as a function of particle size for various assumed input cumulative mass distri- butions resulting from electrode rapping. The complete modeling of the reentrainment process must include the task described in item 6 above, which essentially involves the prediction of the rap- ping pulse in the various fields as a function of dust properties and precipitator design and operating parameters. Thus, there are two major subdivisions to the recommended approach for a more rig- orous treatment of the reentrainment process: 1. Expanding the computer program to obtain the capability to calculate time-depend- ent emissions from the existing input data set (Electrical condi- tions, SCA, precipitator geometry, size distribution, etc.) plus a rapping interval -schedule for the various fields and an assumed 13 ------- cumulative mass distribution for the rapping pulse. 2. Prediction of the rapping pulse distribution from dust properties and precipi- tator design parameters. In view of the above considerations, our suggestions for fol- low-on work are as follows: 1) Expansion of computer program a) Develop a flow chart of a computer program based on the existing model, but with the capability of dy- namically representing rapping programs with various intervals for the different fields in the precipitator. b) Develop appropriate mathematical relationships for representing the dynamic behavior of reentrained particulate in the precipitator. The objective is to formulate a collection mechanism theory appro- priate for reentrained dust. c) Examine the data obtained previously with the ob- jective of finding a procedure to represent the sporadic large particle emissions not associated with rapping. d) Develop a FORTRAN program with items 1-3 included. e) Use the expanded program with various assumed cum- ulative mass rapping pulses and the rapping fre- quencies of the rapping programs at the six test sites. Compare computed results with time integrat- ed measurements obtained with impactors. 2) Prediction of rapping pulse size distribution a) Modify existing large particle real-time counting system to allow for traversing of the duct system. Develop procedures for calibrating the readout with absolute value of in situ particle concentrations. b) Design a test program to use the instrument at several sites with the objective of relating the rap- ping pulse (from various fields in the precipitator) to dust properties and precipitator operating para- meters. The test requirements could be less than is normally required for control device evaluation be- cause of the restricted data requirements. 14 ------- c) Correlate results and use in 1 above to expand model capabilities. The two major tasks described above could be conducted simul- taneously or in series. 15 ------- TECHNICAL REPORT DATA (Please read liatructions on the reverse before completing) I REPORT NO. EPA-600/7-78-112 2. 3. RECIPIENT'S ACCESSION NO. 4. TITLE AND SUBTITLE Rapping Reentrainment in a Near Full Scale Pilot Electrostatic Precipitator S. REPORT DATE June 1978 6. PERFORMING ORGANIZATION CODE 7. AUTHOR(S) Grady B. Nichols 8. PERFORMING ORGANIZATION REPORT NO. SORI-EAS-78-019 3489-Final 9. PERFORMING ORGANIZATION NAME AND ADDRESS Southern Research Institute 2000 Ninth Avenue, South Birmingham, Alabama 35205 1O. PROGRAM ELEMENT NO. 1AB012; ROAP 21ADL-027 11. CONTRACT/GRANT NO. 68-02-1875 12. SPONSORING AGENCY NAME AND ADDRESS EPA, Office of Research and Development Industrial Environmental Research Laboratory Research Triangle Park, NC 27711 13. TYPE OF REPORT AND Final; 5/75-4/78 PERIOD COVERED 14. SPONSORING AGENCY CODE EPA/600/13 is. SUPPLEMENTARY NOTES jERL-RTP project officer is Leslie E. Sparks, Mail Drop 61, 919/541-2925. EPA-600/2-76-140 is an earlier related report. 16. ABSTRACT gives results of a research program to identify the character- istics of particulate matter reintroduced into a gas stream flowing through an elec- trostatic precipitator (ESP) attributable to collection electrode rapping. The study included both fundamental and experimental studies of dust layer behavior in a pilot- scale ESP with collection electrodes of a size that approximates those in a full-scale field unit. Results of the pilot study , together with those of a related study of full- scale ESPs collecting flyash from coal-fired boilers, were used to modify the EPA Computer Systems Model of an ESP to more nearly represent the actual behavior of this class of particulate control device. 17. KEY WORDS AND DOCUMENT ANALYSIS DESCRIPTORS b.IDENTIFIERS/OPEN ENDED TERMS c. COSATI Field/Group Air Pollution Combustion Dust Boilers Electrostatic Precipitation Entrainment Mathematical Modeling Fly Ash Coal Air Pollution Control Stationary Sources Particulates Rapping Reentrainment 13B 11G 13H 07D 21B 21D 13A 12A 13. DISTRIBUTION STATEMENT Unlimited 19. SECURITY CLASS (This Report/ Unclassified 21. NO. OF PAGES 21 20. SECURITY CLASS (This page) Unclassified 22. PRICE EPA Form 2220-1 (9-73) 16 ------- |